Skip to main content

QUALITY ASSURANCE AND REDUCTION OF LEAD TIME FOR CUTTING OPERATIONS

Objective

Managing modern manufacturing equipment requires reliable and updated information on processes, tools; machines and materials. Particularly for SME's the information must be related to small batches and customer related production.

This project aims at the generation of knowledge of cutting processes in machining centres; resulting in a better controlled quality of the product, an improved productivity and a reduced lead time.
A project was created to provide the process planner of a small or medium sized enterprise with a tool that can support him in the selection of methods, cutting tools and conditions for finishing operations. The results were as follows:
knowledge was acquired on parameters that influence quality, lead time, and typical values for obtainable quality parameters;
knowledge was acquired on the performance of different sorts of tools in finishing operations;
specific test procedures for the measurement of quality and for the assessment of method and tool selection were developed;
a method for the theoretical evaluation of roughness for comparative studies was established;
insight into the influence of dispersion within a batch of inserts was gained;
improved knowledge on the effects of predrilling on the final quality was acquired;
a new software for the calculation of cutting conditions was elaborated;
extensive tests were executed with the newest tools;
the relations between superficial residual tresses and machining conditions in aluminium were elaborated, and introduced in machining models;
test procedures for stability, capability and accuracy for machine tools were developed that can be applied by machine shops. A prototype planning system was developed to document the results in a structured way, validate end results and communicate the results to industry. The prototype is distinct from other feature based process planning systems in that it can explain its decisions with respect to method and tool selection. Texts are associated with selection rules describing test results. The knowledge generated can be used by companies which use cutting processes:
to improve the quality of their products;
to decrease manufacturing costs. This sort of knowledge can be used in books, training sessions, software for process planning, and also for computer aided design/manufacture systems. The model describing the relation between cutting parameters and residual stresses will improve the quality of the manufacturing process of vital parts in the Aerospace industry.
We will try to reach these aims by :

1) evaluation of existing logic procedures and determination f new ones, based on existing software,

2) tests of machine tools,

3) tests of cutting tools,

4) development of models,

5) evaluation and test of acquired rules, recommendations and knowledge.

The knowledge generated in the project will be made available to SME's by :

- a methodological guide with rules and recommendations

- a database with data on tools, materials and machines including rules and recommendations for the application of these.

Furthermore the developed models will be introduced in software for optimising the choice of cutting conditions.

Coordinator

Stichting voor Produktietechniek
Address
Pettelaarpark 21 90105
5200 MA S-hertogenbosch
Netherlands

Participants (5)

Aérospatiale Société Nationale Industrielle SA
France
Address
37 Boulevard De Montmorency
75781 Paris
Centre Technique des Industries Mécaniques (CETIM)
France
Address
52 Avenue Félix Louat
60304 Senlis
Centre de Recherches Scientifiques et Techniques de l'Industrie des Fabrications Metalliques - CRIF/WTCM
Belgium
Address
Celestijnenlaan 300C
3001 Heverlee
Nederlandse Organisatie voor Toegepast Natuurwetenschappelijk Onderzoek
Netherlands
Address

2595 CL Den Haag
Swedish Institute of Prod Eng Research
Sweden
Address
Moelndalsvaegen 85
41285 Goeteborg